1996 TOYOTA RAV4 Service Repair Manual

D02208
ON
P
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
DI−169
1996 RAV4 (RM447U)
2 Check PATTERN SEL SW2.
When using TOYOTA hand−held tester:
PREPARATION:
(a) Connect the TOYOTA hand−held tester to the DLC3.
(b) Turn the ignition switch ON and TOYOTA hand−held tes-
ter main switch ON.
CHECK:
Read the PATTERN SEL SW2 signal on the TOYOTA hand−
held tester.
OK:
Pattern select switch pushed in:
PATTERN SEL SW2 .......... ON
Pattern select switch pushed once again:
PATTERN SEL SW2 .......... OFF
When not using TOYOTA hand−held tester:
PREPARATION:
Turn the ignition switch ON.
CHECK:
Measure the voltage between terminal P of the ECM and body
ground when the pattern select switch is set to the PWR (POW-
ER) position and NORM (NORMAL) position.
OK:
Pattern Select SwitchVoltage
PWR7.5 − 14 V
NORMBelow 1 V
HINT:
The ECM uses the normal pattern signal if the power signal is
not input.
OK Proceed to next circuit inspection shown on
problem symptoms table (See page DI−141).
NG

Q08779
3
1
DI−170
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A241E)
1996 RAV4 (RM447U)
3 Check pattern select switch.
PREPARATION:
Remove the pattern select switch.
CHECK:
Check the resistance between terminals 1 and 3 of the pattern
select switch connector when the select switch is set to PWR
and NORM positions.
OK:
PatternResistance
PWR0 Ω (continuity)
NORM∞Ω〈open)
NG Replace pattern select switch.
OK
4 Check harness and connector between battery and pattern select switch, and
pattern select switch and ECM (See page IN−30).
NG Repair or replace harness or connector.
OK
Check and replace ECM.

DI40R−02
Vehicle Brought to Workshop
Customer Problem Analysis
Check DTC and Freeze Frame Data (Pre−check)
Record or Print DTC and Freeze Frame Data P.
DI−173
Clear DTC and Freeze Frame Data P. DI−173
Visual Inspection
Setting the Check Mode Diagnosis P.
DI−173
1
Items insideare titles of pages in this manual, with the
page number indicated in the bottom portion. See the indicated
pages for detailed explanations.

Connect the OBD II scan tool or TOYOTA hand−held tester to DLC3.
If your display shows ”UNABLE TO CONNECT TO VEHICLE” when you have connected the
scan tool / TOYOTA hand−held tester, inspect DLC3 P.
DI−173
2
3
4
5
6
Symptom does not occur
Problem Symptom Confirmation8
7Symptom Simulation
P. I N−XXX
Symptom occurs
DTC CheckP. DI−173OK Code11Preliminary Check
P.
DI−173
DTC Chart
P. DI−189Mechanical System Test
P.
DI−173
Manual Shifting Test
P.
DI−173 OK
OK
Chapter 1
(Electronic)Chapter 2
(On−Vehicle)OKChapter 3
(Off−Vehicle)OK Matrix Chart of Problems Symptoms − P. DI−192
Circuit
Inspection O/D Cancel Signal Circuit Check
 Stop Light Signal Check
NG
Parts Inspection
NG
NGNG
Identification of ProblemRepairConfirmation TestEnd
NG
NG
13NG
15 16
17 18 9
10
P. DI−192
P. DI−196 − DI−229 P. DI−172
12
14
P. DI−192P. DI−192
Step 2, 3, 4, 6, 9, 15, 18:
Diagnostic steps permitting the use of the TOYOTA
hand−held tester or TOYOTA brake−out−box.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−171
1996 RAV4 (RM447U)
AUTOMATIC TRANSAXLE (A540H)
HOW TO PROCEED WITH TROUBLESHOOTING
Troubleshoot in accordance with the procedure on the following pages.

DI40S−01
Transaxle Control
System Check SheetInspector ’s
Name:
Customer ’s Name
Registration No.
Registration Year
Frame No.
Date Vehicle
Brought InOdometer Readingkm
mile / /
/ /
Date Problem
Occurred
Frequency Prob-
lem Occurs?/ /
 Continuous  Intermittent ( times a day)
Symptoms
 Vehicle does not move (  Any position  Particular position )
 No up−shift (  1st → 2nd  2nd → 3rd  3rd → O/D )
 No down−shift (  O/D → 3rd  3rd → 2nd  2nd → 1st )
 Lock−up malfunction
 Shift point too high or too low
 Harsh engagement (  N → D  Lock−up  Any drive position )
 Slip or shudder
 No kick−down
 Others
Check ItemMalfunction
Indicator Lamp
DTC Check
1st Time
2nd Time Normal code  Malfunction code (Code )  Normal Remains ON
 Normal code  Malfunction code (Code ) DI−172
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
CUSTOMER PROBLEM ANALYSIS CHECK

DI40T−02
Q08848
Q08736
TOYOTA Hand−held Tester
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−173
1996 RAV4 (RM447U)
PRE−CHECK
1. DIAGNOSIS SYSTEM
(a) Description.
When troubleshooting OBDII vehicles, the only dif-
ference from the usual troubleshooting procedure
is that you connect the OBDII scan tool complying
with SAE J1978 or TOYOTA hand−held tester to the
vehicle, and read off various data output from the
vehicle’s ECM.
OBD ll regulations require that the vehicle’s on−
board computer lights up the Malfunction Indicator
Lamp (MIL) on the instrument panel when the com-
puter detects a malfunction in the computer itself or
in drive system components which affect the vehicle
emissions. In addition to the MIL lighting up when
a malfunction is detected, the applicable DTCs pre-
scribed by SAE J2012 are recorded in the ECM
memory (See page DI−14).
If the malfunction does not reoccur in 3 trips, the MIL goes off
but the DTCs remain recorded in the ECM memory.
To check the DTCs, connect the OBDII scan tool or
TOYOTA hand−held tester to the DLC3 on the ve-
hicle. The OBDII scan tool or TOYOTA hand−held
tester also enables you to erase the DTCs and
check freezed frame data and various forms of en-
gine data. (For operating instructions, see the OB-
DII scan tool’s instruction book.)
DTCs include SAE controlled codes and Manufac-
turer controlled codes.SAE controlled codes must
be set as prescribed by the SAE, while Manufactur-
er controlled codes can be set freely by the
manufacturer within the prescribed limits (See page
DI−189).

Q08848
DI−174
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
The diagnosis system operates in normal mode
during normal vehicle use, and also has a check
mode for technicians to simulate malfunction symp-
toms and perform troubleshooting. Most DTCs use
2 trip detection logic (*) to prevent erroneous detec-
tion. By switching the ECM to check mode when
troubleshooting, the technician can cause the MIL
to light up for a malfunction that is only detected
once or momentarily (TOYOTA hand−held tester)
(See step 3).
*2 trip detection logic:
When a logic malfunction is first detected, the mal-
function is temporarily stored in the ECM memory.
If the same malfunction is detected again during the second test
drive, this second detection causes the MIL to light up.
2. Normal Mode:
INSPECT DIAGNOSIS
(a) Check the MIL.
(1) The MIL comes on when the ignition switch is turned
ON and the engine is not running.
HINT:
If the MIL does not light up, troubleshoot the combination meter
(See page BE−2).
(2) When the engine starts, the MIL should go off. If the
lamp remains on, the diagnosis system has a mal-
function or abnormality in the system.
(b) Check the DTC.
NOTICE:
TOYOTA hand−held tester only:
When the diagnostic system is switched from the normal
mode to the check mode, it erases all DTCs and freezed
frame data recorded in the normal mode. So before switch-
ing modes, always check the DTCs and freezed frame data,
and note them down.
(1) Prepare the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester.
(2) Connect the OBD II scan tool or TOYOTA hand−
held tester to the DLC3.
(3) Turn the ignition switch ON and turn the OBD II scan
tool or TOYOTA hand−held tester switch ON.
(4) Use the OBD II scan tool or TOYOTA hand−held
tester to check the DTCs and freezed frame data.
Note them down (For operating instructions, see
the OBDII scan tool’s instruction book.).

FI3605
ON
OFF
0.13 sec.
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
DI−175
1996 RAV4 (RM447U)
(5) See page DI−189 to confirm the details of the
DTCs.
NOTICE:
When simulating symptoms with an OBD II scan tool (ex-
cluding TOYOTA hand−held tester) to check the DTCs, use
the normal mode. For codes on the DTC chart subject to ”2
trip detection logic”, turn the ignition switch off after the
symptoms have been simulated for the first time. Then re-
peat the simulation process again. When the program has
been simulated twice, the MIL lights up and the DTCs are
recorded in the ECM.
3. Check Mode:
INSPECT DIAGNOSIS
HINT:
TOYOTA hand−held tester only:
Compared to the normal mode, the check mode has high sens-
ing ability to detect malfunctions.
Furthermore, the same diagnostic items which are detected in
the normal mode can also be detected in the check mode.
(a) Check the DTC.
(1) Initial conditions.
Battery positive voltage 11 V or more.
Throttle valve fully closed
Transaxle in the PARK position
Air conditioning switched off
(2) Prepare the TOYOTA hand−held tester.
(3) Connect the TOYOTA hand−held tester to the
DLC3.
(4) Turn the ignition switch ON and switch the TOYOTA
hand−held tester ON.
(5) Switch the TOYOTA hand−held tester from the nor-
mal mode to the check mode (Check that the MIL
flashes.).
(6) Start the engine (The MIL goes off after the engine
start.).
(7) Simulate the conditions of the malfunction de-
scribed by the customer.
NOTICE:
Leave the ignition switch ON until you have checked the
DTCs, etc.
(8) After simulating the malfunction conditions, use the
TOYOTA hand−held tester diagnosis selector to
check the DTCs and freezed frame data, etc.
HINT:
Take care not to turn the ignition switch OFF. Turning the ignition
switch off switches the diagnosis system from check mode to
normal mode, so all DTCs, etc. are erased.
(9) After checking the DTC, inspect the applicable cir-
cuit.

Q08495
DLC3 DI−176
− DIAGNOSTICSAUTOMATIC TRANSAXLE (A540H)
1996 RAV4 (RM447U)
(b) Clear the DTC.
The following actions will erase the DTCs and
freezed frame data.
Operating the OBD II scan tool (complying with SAE
J1978) or TOYOTA hand−held tester to erase the
codes (See the OBD II scan tool’s instruction book
for operating instructions.).
NOTICE:
If the TOYOTA hand−held tester switches the ECM from the
normal mode to the check mode or vice−versa, or if the
ignition switch is turned from ON to ACC or OFF during the
check mode, the DTCs and freezed frame data will be
erased.
(c) Inspect the DLC3.
The vehicle’s ECM uses V.P.W. (Variable Pulse Width) for
communication to comply with SAE J1850. The terminal
arrangement of DLC3 complies with SAE J1962 and
matches the V.P.W. format.
Terminal No.Connection/Voltage or ResistanceCondition
2Bus  Line/Pulse generationDuring communication
4Chassis Ground − Body/1 Ω or lessAlways
5Signal Ground − Body/1 Ω or lessAlways
16Battery Positive − Body/9 − 14 V or 1 Ω or lessAlways
HINT:
If your display shows ”UNABLE TO CONNECT TO VEHICLE”
when you have connected the cable of the OBD II scan tool or
TOYOTA hand−held tester to the DLC3, turned the ignition
switch ON and operated the scan tool, there is a problem on the
vehicle side or tool side.
If communication is normal when the tool is connected to
another vehicle, inspect the DLC3 on the original vehicle.
If communication is still not possible when the tool is con-
nected to another vehicle, the problem is probably in the
tool itself, so consult the Service Department listed in the
tool’s instruction manual.